Laminated polymer with integrated lighting, sensors and electronics

ABSTRACT

This invention relates to laminated polymer as a host for solid state lighting, sensors, energy generation and storage devices and other electronics that are contained within the transparent non-glass interlayers or air cavities of the laminated polymer.

FIELD OF THE INVENTION

This invention relates to laminated polymer comprised of at least twolayers of transparent polymer separated by a transparent non-glassinterlayer or an air cavity wherein solid state lighting, sensors,energy generation and storage devices and other electronics arecontained within the transparent non-glass interlayer or air cavity.

TECHNICAL BACKGROUND OF THE INVENTION

Developments being achieved in the fields of solid state lighting,sensors, energy generation and storage devices and other electronicshave resulted in products in these areas with reduced imprint and novelfeatures. There is a continual interest in incorporating thesedevelopments into structures that are attractive for architectural,automotive and other uses.

An objective of this invention is to use the non-glass interlayer and/orthe air cavity in laminated polymer to contain solid state lighting,sensors, energy generation or storage devices and other electronics toenhance the functionality and the aesthetics of the laminated polymer.

SUMMARY OF THE INVENTION

This invention provides a laminated polymer comprised of at least twolayers of transparent polymer with adjacent transparent polymer layersseparated by a transparent solid non-glass interlayer or an air cavity,wherein at least one transparent non-glass interlayer or air cavitycontains a device comprised of at least one element selected from thegroup consisting of solid state lighting, heat sensors, light sensors,pressure sensors, thin film capacitance sensors, photovoltaic cells,thin film batteries, liquid crystal display films, suspended particledevice films, and transparent electrical conductors.

DETAILED DESCRIPTION OF THE INVENTION

This invention relates to laminated polymer comprised of transparentpolymer layers separated by a transparent solid non-glass interlayer oran air gap and to the utilization of the transparent solid non-glassinterlayer or the air cavity between the transparent polymer layers ofthe laminated polymer for the integration of a broad range of functionsthat enhance the functionality and the aesthetics of the laminatedpolymer. The laminated polymer is comprised of at least two layers oftransparent polymer with adjacent transparent polymer layers separatedby a transparent solid non-glass interlayer or an air cavity. Oneembodiment of the invention is a laminated polymer comprised of twolayers of transparent polymer separated by a transparent solid non-glassinterlayer.

The laminated polymer acts as a host that allows digital and thin filmtechnologies to be integrated into or alongside the transparent solidnon-glass interlayer or into the air cavity. This allows the transparentsolid non-glass interlayer to serve two possible purposes, that ofproviding mechanical strength to the laminated polymer and that as ahost for a device that adds additional functions to the laminatedpolymer. Similarly, it allows the air cavity to serve two purposes, thatof thermal insulator and that as a host for a device that addsadditional functions to the laminated polymer. As used herein,“transparent”, when used in connection with transparent polymer layer ortransparent solid non-glass interlayer, means a polymer layer or a solidnon-glass interlayer which transmits light with no appreciablescattering as well as a polymer layer or a solid non-glass interlayerwhich is translucent, i.e., which partially transmits light. The degreeof transparency required of the transparent polymer layer or transparentsolid non-glass interlayer will usually be dictated by how the laminateis to be used. If the use requires as completely transparent a laminateas possible, e.g., for use as a window, the transparent polymer layerand transparent solid non-glass interlayer should transmit light with noappreciable scattering. For other uses, a transparent polymer layer anda transparent solid non-glass interlayer that partially transmit lightcan be quite acceptable.

The invention provides that at least one transparent solid non-glassinterlayer or air cavity contain a device comprised of at least oneelement selected from the group consisting of solid state lighting, heatsensors, light sensors, pressure sensors, thin film capacitance sensors,photovoltaic cells, thin film batteries, liquid crystal display films,suspended particle device films, and transparent electrical conductors.When a transparent solid non-glass interlayer is used, the interlayermay be perforated to provide space for the elements of the device. Suchperforations can also serve as light scattering centers when the sourceof light is placed along the edge of the transparent solid non-glassinterlayer. Alternatively, the elements of the device may be adjacent tothe transparent solid non-glass interlayer. Preferred as the transparentsolid non-glass interlayer is a Butacite® PVB (polyvinyl butyral)interlayer available from E. I. du Pont de Nemours and Company,Wilmington, Del. Transparent electrical conductors such as indium tinoxide can be deposited directly onto the transparent polymer.

The solid state lighting can be in the form of light-emitting diodes(LEDs), an optoelectrical device consisting of a p-n junction that emitslight (ultraviolet, visible or infrared radiation) in response to aforward current passing through the diode. LEDs are made using inorganicmaterials. The solid state lighting can also be in the form of organiclight-emitting diodes (OLEDs). The OLEDS can polymeric light-emittingdiodes (pLEDs) or small molecule organic light-emitting diodes(SMOLEDs). Transparent electrical conductors can be used to providemeans to apply an activating voltage to the individual LEDs or OLEDs.Indium tin oxide is a preferred transparent electrical conductor. Thesource of illumination can also be in the form of an electroluminescent(EL) film. When the source of light is placed along the edge of thetransparent solid non-glass interlayer it can be used to enhance imagesprinted on the transparent solid non-glass interlayer. A microprocessorchip to control the solid state lighting can be provided either as partof the device contained in at least one transparent solid non-glassinterlayer or air cavity or can be provided externally to the laminatedpolymer. The microprocessor chip can be programmed to cause the solidlighting to display a sequence of images. The images can be in the formof a pictorial or aesthetic display or text. Motion detectors can beused to detect motion and the image changed accordingly. For example,when a thin film capacitance sensor is made part of the device, themotion of an object, such as a hand, can change the display.Alternatively, a pressure sensor can detect the application of pressureto the surface of the laminated polymer and provide a change in thedisplay. The laminated polymer remains transparent over the parts of thelaminated polymer where there is no solid state lighting or where thesolid state lighting is not activated. The portion of the laminatedpolymer where the solid state lighting is activated displays images andinformation such as temperature, time, stock prices, etc. as well asprogrammable text and messages.

When the polymer layers are sufficiently thin, the laminated polymerwill be flexible and can be adapted to various shapes and forms. Such aflexible laminated polymer is especially useful when curved or othernon-flat displays are desired. Depending on the degree of flexibility,the flexible laminated polymer may need to be attached to a supporthaving the desired shape. Alternatively, the flexible laminated polymercan be contained within a glass support. When OLEDs are used as thesource of illumination, the glass container would also provide amoisture and oxygen barrier for the OLEDs and thereby improve the OLEDlifetime.

As the polymer thickness increases and the mechanical strength of thelaminated polymer increases the laminated polymer is conformable tovarious shapes and forms.

When the polymer layers are sufficiently thick to provide mechanicalstrength and stability to the laminated polymer structure, the laminatedpolymer can serve as an external or internal window, as an external orinternal wall or surface, or as a display surface.

Another device that can be incorporated in the transparent non-glassinterlayer is one that converts energy received in the form of lightfrom the sun or other light sources into electrical energy that can bestored in a battery and used to power LEDs, OLEDs, electroluminescentfilms, liquid crystal display films, electrochromic suspended particledevice films, etc. For example, the device can be comprised of a thinfilm photovoltaic panel, a rechargeable thin film lithium battery andtransparent indium tin oxide films to conduct electricity between thevarious elements. Alternatively, the battery could be used to poweranother device not within the window. With the addition of amicroprocessor to control the illumination, the energy stored in thebattery can be used to provide different types of displays in the windowduring different times of the day. For example, the display could supplyinformation, advertising, etc. during daylight hours; it could supplyillumination during the evening hours; it could act as a night-light.Since the lithium battery is opaque and typical reasonably pricedphotovoltaic cells are opaque, these elements are localized in oneportion area of the transparent non-glass interlayer. This devicecomprised of a thin film photovoltaic panel and a rechargeable thin filmlithium battery can also be used in other embodiments of the laminatedpolymer.

The embodiment of the invention of a laminated polymer comprised of twolayers of transparent polymer separated by a transparent solid non-glassinterlayer, i.e., polymer-interlayer-polymer, or a laminated polymercomprised of three layers of transparent polymer and two transparentsolid non-glass interlayers, i.e.,polymer-interlayer-polymer-interlayer-polymer, are particularly usefulfor illumination or displays and especially for providing a flexiblelaminated polymer for these uses. The transparent solid non-glassinterlayer can be illuminated by LEDs or OLEDs in the transparent solidnon-glass interlayer or by LEDs or OLEDs positioned at the edges of thetransparent solid non-glass interlayer. The laminated polymer comprisedof three layers of transparent polymer and two transparent solidnon-glass interlayers provides with each transparent solid non-glassinterlayer containing a lighting device provides an even wider varietyof lighting variations than the laminated polymer comprised of twolayers of transparent polymer separated by a transparent solid non-glassinterlayer. With two lighting devices within the laminated polymer,various combinations of lighting can be obtained.

EXAMPLE OF THE INVENTION

This Example demonstrates the use of a flexible laminated polymer of theinvention as a source of illumination. The flexible laminated polymercontaining a PLED lighting device was fabricated in the followingmanner. A flexible substrate of poly(ethylene terephthalate) (PET) sheetwas partially coated with an indium tin oxide (ITO) film to serve as theanode of the device. A poly(3,4-ethylenedioxythiophene) (PEDOT) blend,CH8000 (commercially available from Bayer AG, Germany) was spin-coatedat 1,000 rpm for 80 seconds, in air, onto the ITO-coated PET. Theresulting film was dried on a hot plate at 120° C. for 1 minute and thenovernight under vacuum at 90° C. A solution of a yellow emitter PDY®32(commercially available as a pre-made solution from Covion OrganicSemiconductors, GmbH, Frankfurt, Germany) was spin-coated at 330 rpm for30 seconds, followed by 1000 rpm for 20 seconds, onto the PEDOT thinfilm. The PEDOT and PDY®132 were removed in the areas where the cathodeand anode must make contact with the current source. A low work functionmetal, Ca, was vapor deposited on the film of PEDOT and PDY®32 to athickness of 10 to 30 nm. A layer of aluminum was vapor deposited on topof the Ca layer to a thickness of 300 nm to complete the cathodeformation. A layer of uv-curable epoxy was spread over the device, butleaving the contact area uncovered. A piece of poly(ethyleneterephthalate) (PET) sheet was placed on top of the epoxy, and the epoxywas cured with uv light. When a battery was connected to the electrodes,the entire device emitted yellow light.

1. A laminated polymer comprised of at least two layers of transparent polymer with adjacent polymer layers separated by a transparent solid non-glass interlayer or an air cavity, wherein at least one said transparent non-glass interlayer or said air cavity contains a device comprised of at least one element selected from the group consisting of solid state lighting, heat sensors, light sensors, pressure sensors, thin film capacitance sensors, photovoltaic cells, thin film batteries, liquid crystal display films, suspended particle device films, and transparent electrical conductors.
 2. The laminated polymer of claim 1, comprised of two layers of transparent polymer separated by a transparent solid non-glass interlayer.
 3. The laminated polymer of claims 1 or 2, wherein said device is comprised of solid state lighting.
 4. The laminated polymer of claim 3, wherein said solid state lighting is in the form of at least one light emitting diode.
 5. The laminated polymer of claim 3, wherein said solid state lighting is in the form of at least one organic light emitting diode.
 6. The laminated polymer of claim 3, wherein said solid state lighting is in the form of an electroluminescent film.
 7. The laminated polymer of claim 3, wherein said device is further comprised of transparent electrical conductors to provide means to apply an activating voltage to said solid state lighting.
 8. The laminated polymer of claim 7, wherein said transparent electrical conductors are indium tin oxide films.
 9. The laminated polymer of claim 7, wherein said device is further comprised of a microprocessor chip that is programmed to control said solid state lighting and to cause said solid state lighting to display a sequence of images.
 10. The laminated polymer of claim 9, wherein said microprocessor chip is programmed to cause said solid state lighting to display text.
 11. The laminated polymer of claim 7, wherein there is provided externally to said laminated polymer a microprocessor chip that is programmed to control said solid state lighting and to cause said solid state lighting to display a sequence of images.
 12. The laminated polymer of claim 11, wherein said microprocessor chip is programmed to cause said solid state lighting to display text.
 13. The laminated polymer of claim 3, wherein the laminated polymer is flexible and can be adapted to various shapes and forms.
 14. The laminated polymer of claim 13, wherein said solid state lighting is in the form of at least one light emitting diode.
 15. The laminated polymer of claim 13, wherein said solid state lighting is in the form of at least one organic light emitting diode. 